No 4wd-Fuse Blows-Video-1995 K2500 Suburban 6.5TD

My exes four-wheel drive hasn't worked in a couple of years she just told me. I had upgraded to the motorized four wheel drive actuator several years ago, but we split up over three years ago, and we haven't had much contact. Anyways I decided to try fix the truck, as she's being stiffed or whatever by several local shops. I removed the top of the fuse box under the hood and I found the brown power wire that I tapped into the fuse box, it was disconnected. No idea why, maybe when the guys were trying to stiff her to tell her she needed a new injection pump? Anyways I reconnected it, no four-wheel drive. I checked the fuse at the side of the dash, it was blown, I replaced it and it immediately blew when I engaged 4 wheel drive with the lever on the floor. I went under the truck and disconnected the transfer case switch adjacent to the leaver, and the fuse stopped blowing. So I remove the switch and everything seems to be kosher. I read the post by 95 6.5.
I have another 6.5 4wd in my shop, I'll try swap the switch in case it's internally shorting

I'm still stuck in the same place, I put the switch in from my other truck and the fuse still blows, and I've tried running a test lamp across the fuses, a friend suggested when I found the short the lamp will go out, but it didn't work, because even though I jiggled all the wires from one end to the other, the lamp still stayed lit. Another friend who watched my video suggested I may have a bad computer, I wish I knew what was going on.

Gotta be a short to ground somewhere,have you checked every wire on it's entire length? We have the same truck except the engines and mine works as it should.I remember the wires going to the transfer case switch were very close the the exhaust pipe and had to zip tie them out of the way,maybe yours has grounded somewhere there?One last suggestion it to check the transfer case relay,maybe it's bad.....

The wires thread up in-between between the starter and block. using my friends suggested test lamp across the transfer case fuse, nothing changed. A friend of mine has a similar truck, gas engine, and he thought maybe the computer? But we're just throwing darts at the wall. I guess I could unplug the four wheel drive relay. I'm so bad at 12 volt wiring. Luckily I have an almost identical diesel truck in the shop to compare notes with

Try swapping relays,might get lucky.I'm not too good at wiring either,I guess I get lucky when stuff works when I'm done LOL One more question....after the upgrade did it ever work?

Where is the relay?

According to ALLDATA it's supposed to be on the firewall behind the engine(check pic I posted earlier),just checked my engine compartment and saw I didn't have one at that location.So...at this point I'm not sure it even has one.

Try swapping the actuators just to eliminate that variable. Mine has the pushbutton 4X and gas engine but it was doing exactly what yours is doing when the actuator failed. Also, I believe the instructions on the motorized actuator conversion call for scotch clamping that brown wire to a hot somewhere above the trans. Your solution sounds cleaner but I wonder if you are overloading something else.

I swapped two different actuators, same result. And it worked for several years, until two or three years ago when my ex said four wheel drive wasn't working. But we were barely on speaking terms, obviously that's changed because $600 in parts just arrived for me to fix her truck. The fuse pops quickly, which means it's a dead short, not overloaded.